Electric control valve

ABSTRACT

An electrically operated control valve adapted to fit within a bore of a cooperating apparatus. The valve including an interchangeable stator and lower body member. The valve further includes a valve means having a swingable self-aligning valve closure element.

The invention relates to electrically controlled two-way valves forcontrolling the admission of fuel through an adjacent passage and moreparticularly to a valve that contains a self-aligning closure element.

As mentioned, the present invention relates to an electricallycontrolled valve. The valve has wide ranging applicability, however aspecific application of the present valve is to control the flow of fuelinto a timing chamber of an electrically controlled unit injector havinga single solenoid control valve. Such a unit injector is shown in thecommonly assigned U.S. patent to Sisson et al., U.S. Pat. No. 4,281,792,which issued Aug. 4, 1981. To control the operation of such a unitinjector, the control valve must be able to fit into a small envelopeand be able to provide an effective seal against the pressure adjacentto its outflow passage, which may be as high as 20,000 psi (1400 bars)while permitting a minimum amount of leakage. To meet the firstrequirement imposed, the present invention advantageously eliminates theexterior housing which is often used to retain the electro-mechanicalelements of similar valves. As illustrated below, the present inventioncomprises a separate stator and lower body member that are fitted to acooperating bore leading to a pressure chamber of an apparatus such asthe above-noted unit injector. In this respect, an advantage of thepresent invention is that the stator and lower body member arecompletely interchangeable therein permitting easy replacement orinterchangeability to meet varying operational demands. A furtheradvantage of the present invention is the ability to seal against highpressure while permitting a minimum leakage. This is advantageouslyachieved by incorporating within the lower body member a self-aligningface. The self-aligning valve face includes means to permit the valveface to rotate relative to its coacting valve seat thus permitting thecontrol valve to compensate for misalignments of the various valvecomponents. This feature permits the valve face to rotate about a valvecap. Consequently, the only tolerances which are significant incontrolling the leakage through the valve are the flatness of thesealing surfaces. A further advantage of the present invention is thatthe fluid flow is directed through the lower body member to thereby coolthe valve. In addition, the actuation distance or gap as described belowcan be mechanically set rather than determined by the tolerances of thecooperating parts.

Accordingly, the present invention comprises a two piece control valveadapted to be received within a bore of a cooperating apparatus. Thecontrol valve comprising: a stator and a lower body member positionedadjacent to the stator. The lower body member includes a plurality ofpassages such as an axially extending bore.

The valve further includes armature means including a magnetic memberand a piston member reciprocable within the axially extending bore andvalve means and movable with the armature in response to the magneticfield generated by the stator for restricting the outflow of fueltherefrom.

The valve means includes a movable valve closure element having a valveface and a stationary member defining a valve seat.

The valve means further including self aligning means to permit thevalve face to align with and seal upon the valve seat; thisself-aligning means comprising: a nut having a spherically shaped uppersurface. The nut is secured to an end of the piston member that extendsfrom said lower body member. The self-aligning means further includes acup-shaped valve cap having walls, the end of which define the valveface and a bottom having an opening therethrough. The bottom includes alower surface having a conical shape and a spherically shaped uppersurface. The opening in the bottom being adapted to permit the valve capto be mounted onto the extending portion of the piston member; theself-aligning means further including a preload spacer having an uppersurface and a bottom surface and a centrally located opening adapted toreceive the piston member, the bottom of the preload spacer having aconically shaped surface that is positioned in contacting engagementwith the upper surface of the valve cap, and spring means for biasingthe upper surface of the preload spacer towards an open condition.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic diagram illustrating a cross-sectional view of thepresent invention.

FIG. 2 further illustrates the details of the self-aligning closureelement shown in FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

Reference is now made to FIG. 1 which illustrates the control valve 10comprising a stator 12 and a lower body member 14. The lower body memberhouses an armature assembly 16 and valve means 18. The two piece controlvalve 10 is received within a bore 22 of a coacting apparatus or housingthat is generally designated 20. As previously mentioned, the apparatusmay be a unit injector similar to that described in the U.S. Pat. No.4,281,792, which is expressly incorporated by reference. The apparatusor injector would include a supply or first passage 24 that terminatesin the lower end of the bore 22 and an outflow or second passage 26 thatcommunicates with a pressure or timing chamber (not shown). It is not arequirement of the invention that the stator 12 be completely receivedwithin the bore 22. The lower body member 14 is seated upon a shoulder28. The control valve 10 is maintained in a fastened orientation withinthe housing 20 by means of a clamp 30. Alternatively the clamp 30 can beeliminated by substituting a threadable connection between the stator 12and bore 22.

Returning to the discussion of the control valve 10. The control valve10 comprises a stator 12 of a known construction and magnetically sizedto produce a desired magnetic flux upon actuation. The stator 12 mayalso include an annular groove 32 and O-ring 34 that is adapted to bebiased against the walls of the bore 22. The lower body member 14comprises a truncated exterior wall 40 that defines in cooperation withthe lower portion of bore 22, a fuel chamber 42. The lower body member14 further includes an upper surface 44, adapted to engage a matingsurface of the stator 12. A partially extending first bore 46 isfabricated within the upper surface 44. This bore serves as an enclosurefor the armature assembly 16. The bottom surface of the bore 46 mayfurther include an upraised boss 48. The bore 46 may be formed by aseparate washer-like spacer member (not shown). The first bore 46 iscommunicated to the wall 40 (and to the fuel chamber 42) by a fuelpassage 50. The lower body member 14 further includes an axiallyextending second bore 54 and are inwardly extending third bore 52oppositely situated from the first surface 44. The lower portion of thefirst bore 46 is also communicated with the upper portion of an axiallyextending spring chamber of annular bore 56. The annular bore 56comprises a spring chamber to house a bias spring 60. The annular bore56 is preferably coaxial to the third bore 52. Fluid communication isachieved between the first bore 46 and the annular bore or springchamber 56 via a fuel passage 64.

The control valve 10 further includes valve means 18. The valve means 18includes a valve seat 70 and a valve closure element 72. The valve seat70 comprises a member 74 that is adapted to fit within the bore 54,having an outwardly positioned surface 76 and a bore 80 extendingtherethrough. The bore 80 terminates in a larger oppositely situatedvalve bore 82 which is the upper portion of the bore 80. It is required,however, that the bore 82 communicate the spring chamber 56 with thebore 80. The valve closure element 72 is movable with the armatureassembly 16. The armature assembly 16 comprises a magneticallyresponsive magnetic member 90 and an axially extending piston member 92.The piston member 92 is positioned within and extends through theaxially extending bore 52 and through the bore 80 in the valve seat 70.The valve closure element 72 is connected to that portion of the pistonmember 92 extending beyond the valve seat 70.

Reference is now made to FIG. 2 which illustrates in greater detail, thestructure of the valve means 18. As previously mentioned, the valvemeans 18 comprises a valve seat 70 and the valve closure element 72. Thevalve closure element 72 is connected to the piston member 92. Theclosure element 72 is movable with the piston member 92 for seating uponthe outer surface 76 of the member 74. The valve closure element 72includes a nut 110 threadably attached to the piston member 92, apreload spacer 112 and an intermediate hollow cup-shaped cap 114 havinga sealing face 130. The preload spacer 112 includes an opening 113 thatis adapted to receive the piston member 92. One end of the preloadspacer 112 extends out through the bore 80 while the other end of thepreload spacer extends into the volume formed by the valve bore 82. Thespring 60 is maintained in contacting engagement with the preload spacer112 for biasing the valve closure element 72 apart from the seatingsurface 76 thereby creating a flow path 100. To accommodate for thesituation, where the axis of the piston member 92 and the axis of thebore 52 are skewed relative to one another or to accomodate for the lackof perpendicularity between the surface 76 of member 74 and the axis ofthe piston member 92, the valve closure element 72 further includesself-aligning means for permitting the valve closure element 72 toeffectively seal upon surface 76 of the valve seat 70. In the preferredembodiment of the invention, the self-aligning means includes the nut110 attached to the lower end of the piston member 92. The nut 110includes an upper spherically shaped surface 116. The self-aligningmeans further includes the hollow cup-shaped cap 114 that is rotatablyand slidably situated between the preload spacer 112 and the nut 110.The cup-shaped cap 114, a bottom 118 having an opening 120 and a lowerconically shaped surface 122 which provides a line contact with thespherical surface 116 of the nut 110. The bottom 118 of the cap 114further includes an upper surface 124 having a spherical contour and awall 119 axially extending from the bottom 118. In the preferredembodiment of the invention, the center of the spherical surface 116 andthe center of the upper surface 124 are the same. Finally, the lowersurface 126 of the preload spacer 112, engaging the upper surface 124 isfabricated to have a conical shape therein providing a line contacttherebetween. The end surface or valve face 130 of wall 119 of the valvecap 114 is machined to a desired flatness to conform to and seat withthe surface 76.

FIG. 1 illustrates the control valve 10 in its open condition whereinthe fuel is received into the fuel chamber 42 from the fuel passage 24.Fuel is communicated to the first bore 46 through the fuel passage 50.The fuel envelopes the magnetic member 90 and flows into the springchamber 56 through the fuel passage 64. Fuel is communicated through thebores 82 and 80 and flows out of the valve through the flow path 100 andinto the outflow or second passage 26 of the cooperating apparatus 20.Upon receipt of an electrical command signal, a magnetic force iscreated to move the member 90 through its stroke generally designated as`a`. The movement of the member 90 causes the valve means 18 to seatupon the surface 76 of member 74 therein terminating fuel flow. It isanticipated that the top surface 116 of the nut 110 will be machinedwith a spherical surface. This spherical surface, in conjunction withthe chamfered or conically shaped lower surface 122 of the bottom 118 ofthe valve cap 114 will permit the valve face 130 to be free to rotate.The mating surface between the sufaces 116 and 122 will be a circularcontact area which may tend to yield slightly when the valve means 18 isclosed to provide an effective seal. The ability of the valve face 130to rotate relative to the nut 110 will allow the valve face 130 to alignitself against the valve seat 70. Consequently as previously mentioned,the only tolerances which will affect the leakage will be the flatnessof the two sealing areas, i.e., 76 and 130. Finally, as previouslymentioned, the upper surface 124 of the valve cap 114 is preferablymachined with a spherical radius which will mate with the chamferedconical shaped lower surface 126 of the preload spacer 112. The contactsurface between the surfaces 124 and 126 will be a circular contact areawhich will provide the valve face 130 with stability in the alignedposition when the valve is open.

Many changes and modifications in the above described embodiment of theinvention can of course be carried out without department from the scopethereof. Accordingly, that scope is intended to be limited only by thescope of the appended claims.

What is claimed is:
 1. A two piece control valve adapted to be receivedwithin a bore of a cooperating apparatus, the control valve comprising:astator; a lower body member positioned adjacent to said stator includinga plurality of passages including an axially extending bore; armaturemeans including a magnetic member and a piston member reciprocablewithin said axially extending bore and situated within the said lowerbody member; valve means, movable with said armature means in responseto the magnetic field generated by said stator for permitting theoutflow of fuel therefrom; said valve means partially situated withinsaid lower body member and including a movable valve closure elementhaving a valve face and a stationary member defining a valve seat; saidvalve means further including self aligning means to permit said valveface to align with and seal upon said valve seat; said self-aligningmeans comprising:a nut having a spherically shaped upper surface andsecured to an end of said piston member extending from said lower bodymember; a cup-shaped valve having walls the end of which define saidvalve face and a bottom having an opening therethrough, said bottomincluding a lower surface having a conically shaped surface and aspherically shaped upper surface, said opening adapted to permit saidvalve cap to be mounted onto the said extending portion of said pistonmember; said self-aligning means further including a preload spacerhaving an upper surface and a bottom surface and a centrally locatedopening adapted to receive said piston member, said bottom of saidpreload spacer having a conically shaped lower surface and positioned incontacting engagement with said upper surface of said valve cap; andspring means for biasing said upper surface of said preload spacertowards an open condition. .Iadd.
 2. A control valve adapted to bereceived within a bore of a cooperating apparatus, the control valvecomprising:a lower body member comprising a plurality of passagesincluding a axially extending bore; armature means including a magneticmember movable in response to a magnetic field and a piston membermovable therewith, reciprocable within said axially extending bore andsituated within said lower body member; a valve seat positioned aboutone of said plurality of passages; valve means, movable with saidarmature means for permitting the flow of fluid through said passage,and partially situated within said lower body member and includingself-aligning means for aligning with and seating upon said valve seat;said self-aligning means comprising:a nut having a spherically shapedupper surface and secured to an end of said piston member extending fromsaid lower body member; a movable closure element comprising: walls theend of which define a valve face and a bottom having an openingtherethrough, said bottom including a conically shaped lower surfaceadapted to engage said upper surface of said nut and a sphericallyshaped upper surface, said opening adapted to permit said closureelement to be mounted onto said piston member; said self-aligning meansfurther including a preload spacer having an upper surface and a bottomsurface and a centrally located opening adapted to receive said pistonmember, said bottom of said preload spacer having a conically shapedlower surface and positionable in contacting engagement with said uppersurface of said closure element; and spring means for biasing said uppersurface of said preloas spacer towards an open condition. .Iaddend..Iadd.
 3. The valve as defined on claim 2 wherein said magnetic field isgenerated by a stator. .Iaddend. .Iadd.4. A control valve comprising;anelectromagnetically actuated armature movable relative to a flowpassage; a valve seat disposed about said flow passage; valve meanssituated in said flow passage comprising a valve closure element,including a valve face, movable with said armature and further includingself-aligning means for permitting said valve face to align with andseal upon said valve seat wherein said self-aligning means comprises: afirst member having a spherically shaped upper surface secured to anextending portion of said armature; a cup-shaped valve cap having wallsthe end of which define said valve face and a bottom having an openingtherethrough, said bottom including a conically shaped lower surface incontacting engagement with the upper surface of said first member and aspherically shaped upper surface, said opening adapted to permit saidvalve cap to receive said extending portion of said armature; saidself-aligning means further including a preload spacer having an uppersurface and a bottom surface and a centrally located opening adapted toreceive said extending portion, said bottom of said preload spacerhaving a conically shaped lower surface and positioned in contactingengagement with said upper surface of said valve cap. .Iaddend. .Iadd.5.The control valve as defined in claim 4 further including means forbiasing said valve closure element in an open condition. .Iaddend..Iadd.6. The control valve as defined in claim 5 wherein said biasingmeans includes:a spring for biasing said upper surface of said preloadspacer towards an open condition. .Iaddend. .Iadd.7. The control valveas defined in claim 4 wherein said first member comprises a nut receivedupon said extending portion. .Iaddend. .Iadd.8. The control valve asdefined in claim 7 wherein said armature includes a magneticallyattractable portion situated in an extension of said flow passage and apiston member depending therefrom, said piston member defining theextending portion of said armature. .Iaddend.